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Komatsu PC12R-8 Service Manual

Komatsu PC12R-8
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WEAM002702
HYDRAULIC EXCAVATOR
PC12R-8
PC12R-8 HS
PC15R-8
PC15R-8 HS
SERIAL NUMBER
PC12R-8 - F31493 and up
PC12R-8 HS - F31493 and up
PC15R-8 - F22262 and up
PC15R-8 HS - F22262 and up
Operation & Maintenance
Manual
Unsafe use of this machine may cause serious injury
or death. Operators and maintenance personnel
must read this manual before operating or maintain-
ing this machine.
This manual should be kept inside the cab for refer-
ence and periodically reviewed by all personnel who
will come into contact with the machine.
WARNING

Table of Contents

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Komatsu PC12R-8 Specifications

General IconGeneral
BrandKomatsu
ModelPC12R-8
CategoryExcavators
LanguageEnglish

Summary

1.1 FOREWORD

1.2 INFORMATION ON SAFETY

1.3 INTRODUCTION

1.3.1 INTENDED USES

Defines the intended applications and authorized optional equipment for the machines.

1.3.2 IMPROPER OR UNAUTHORIZED USES

Details forbidden uses and potential hazards of misuse.

1.3.3 MAIN CHARACTERISTICS

Lists the key features and design aspects of the machines.

1.3.4 RUNNING-IN

Provides instructions for the initial break-in period to ensure proper machine performance.

1.4 PRODUCT IDENTIFICATION

1.4.1 MACHINE SERIAL NUMBER

Explains where to find the unique serial number for identification and service.

1.4.2 MACHINE IDENTIFICATION PLATE

Details the information found on the machine's identification plate, including CE mark.

1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE

Locates serial numbers and emission plates for the engine.

1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER

Identifies the location of the serial number for the travel reduction gear.

1.4.5 SWING REDUCTION GEAR SERIAL NUMBER

Specifies the location of the serial number for the swing reduction gear.

1.4.6 CAB SERIAL NUMBER

Indicates where the serial number for the cab is stamped.

SAFETY AND ACCIDENT PREVENTION

2.1 SAFETY, NOISE AND VIBRATION PLATES

Explains the purpose and location of safety, noise, and vibration plates on the machine.

2.1.1 POSITION OF THE SAFETY PLATES

Illustrates the locations of safety plates on the machine for easy identification.

2.1.2 PICTOGRAMS AND RELEVANT MEANINGS

Explains the meaning of various pictograms and warning symbols used on the machine.

2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB

Shows where noise level plates are located on machines equipped with a cab.

2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY

Shows where noise level plates are located on machines equipped with a canopy.

2.2 GENERAL PRECAUTIONS

Essential general safety rules, devices, guards, and personal protective items.

2.2.1 GENERAL SAFETY RULES

Fundamental rules for safe operation and maintenance.

2.2.2 SAFETY DEVICES AND GUARDS

Importance of using and maintaining safety devices and guards for accident prevention.

2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS

Guidelines on appropriate clothing and PPE for safe operation and maintenance.

2.2.8 PREVENTING BURNS

Safety measures to avoid burns from hot engine parts, fluids, or steam.

2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT

Importance of locating and checking fire extinguishers and first aid kits.

2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT

Guidelines for installing and using optional equipment safely and correctly.

PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE

2.3.1 SAFETY ON THE WORK SITE

Essential safety checks and considerations for the work area before starting operations.

2.3.2 FIRE PREVENTION

Measures to prevent fires by removing flammable materials and checking fluid systems.

2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR’S CAB

Ensuring the operator's cab is clean, organized, and safe for operation.

2.3.4 ROOM VENTILATION

Importance of proper ventilation, especially in confined spaces, to avoid gas hazards.

PRECAUTIONS TO BE TAKEN WHEN WORKING

2.4.1 STARTING THE ENGINE

Steps and safety checks for starting the engine before operating the machine.

2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE

Verifying the blade position to ensure correct travel control operation.

2.4.3 CHECKS FOR TRAVELLING IN REVERSE

Safety measures and checks required when operating the machine in reverse.

2.4.4 MOVING THE MACHINE

Guidelines for safe machine movement, including bucket position and speed.

2.4.5 MOVING ON SLOPES

Specific precautions and techniques for safely moving the machine on slopes.

2.4.6 WORKING ON SLOPES

Safe practices for operating the machine on slopes, including rotation and soil accumulation.

2.4.8 PREVENTING ELECTROCUTION

Critical safety measures and minimum distances to avoid electrocution from overhead power lines.

2.4.13 PARKING THE MACHINE

Procedures for safely parking the machine on level ground and slopes.

TRANSPORTING THE MACHINE ON MOTOR VEHICLES

2.5.1 LOADING AND UNLOADING

Detailed steps and safety precautions for loading and unloading the machine onto vehicles.

2.5.2 TRANSPORT

Considerations for safe transport, including route planning and regulatory compliance.

BATTERY

2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY

Hazards associated with batteries (acid, hydrogen) and necessary precautions.

2.6.2 STARTING WITH BOOSTER CABLES

Correct and safe procedure for starting the engine using booster cables.

PRECAUTIONS FOR THE REMOVAL

2.7 PRECAUTIONS FOR THE REMOVAL

Safety measures and procedures for removing the machine.

PRECAUTIONS FOR MAINTENANCE

2.8.1 WARNING PLATES

Importance of using and placing warning plates during maintenance to prevent accidental startup.

2.8.2 TOOLS

Guidelines for selecting and using appropriate tools for maintenance tasks.

2.8.5 WORKING UNDER THE MACHINE

Safety measures when working underneath the machine, ensuring it is properly supported.

2.8.6 CLEANING THE MACHINE

Proper methods for cleaning the machine, avoiding high-pressure water on sensitive parts.

2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION

Mandatory procedure to stop the engine and secure the machine before any maintenance.

2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP

Safety guidelines for refueling and topping up fluids, preventing spills and fires.

2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL

Critical safety steps when dealing with high-pressure oil, including PPE and leak checks.

SAFETY LOCKS

3.1.1 MACHINE LOCKS

Details the various locking mechanisms (anti-rotation, boom swing, equipment controls) for securing the machine.

GENERAL VIEWS

3.2.1 FRONT GENERAL VIEW

Diagram and labels identifying major components visible from the front of the machine.

3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY

Diagram and labels identifying components for machines equipped with a canopy.

3.2.3 GENERAL VIEW OF THE DRIVER’S SEAT

Labeled diagram of the driver's seat area, identifying controls and instruments.

INSTRUMENTS AND CONTROLS

3.3.1 INSTRUMENTS

Explanation of the hour meter and fuel level indicator.

3.3.2 WARNING LIGHTS

Identifies and explains the function of various warning lights on the dashboard.

3.3.3 SWITCHES AND PUSH BUTTONS

Identifies and explains the function of various switches and push buttons.

3.3.5 MACHINE CONTROLS

Comprehensive guide to all machine control levers, pedals, and their functions.

1-2 - EQUIPMENT CONTROL LEVERS

Detailed explanation of basic and combined maneuvers for equipment control levers.

3-4 - TRAVEL AND STEERING CONTROL LEVERS

Instructions for operating travel and steering control levers for forward/reverse movement.

5 - BOOM SWING CONTROL PEDAL

Procedure for operating the boom swing control pedal for left/right movement.

8 - LEFT SAFETY DEVICE CONTROL LEVER

Operation of the left safety device lever to lock machine movements.

9 - RIGHT SAFETY DEVICE CONTROL LEVER (only on machines with canopy)

Operation of the right safety device lever to lock machine movements.

10 - SPEED INCREASE PEDAL

How to use the pedal to increase machine travel speed.

11 - OPTIONAL EQUIPMENT CONTROL PEDAL

Control of optional equipment using a dedicated pedal.

12 - UPPER STRUCTURE ROTATION LOCKING LEVER

Procedure for locking and unlocking the upper structure rotation.

FUSES AND RELAYS

3.4.1 FUSES

Table detailing fuse positions, colors, capacities, and circuits.

3.4.2 RELAYS

Table listing relay positions and their functions.

GUARDS AND DRIVER’S SEAT

3.5.1 ENGINE HOOD

Safety precautions and procedures for opening and closing the engine hood.

3.5.2 CANOPY

Safety information regarding the ROPS/FOPS certified canopy.

3.5.3 CAB

Safety information regarding the ROPS/FOPS certified cab and its features.

3.5.3.1 SLIDING DOOR

Instructions for operating the sliding cab door safely, including locking mechanisms.

3.5.3.2 FRONT OPENING WINDSHIELD

Procedures for safely opening and closing the front windshield, including wiper connector.

3.5.4 VENTILATION AND HEATING

Explanation of the cab's ventilation and heating system for operator comfort.

3.5.6 SAFETY BELT

Importance of using and maintaining the safety belt for operator protection.

3.5.7 EMERGENCY EXIT

Location and use of the emergency exit hammer and window.

3.5.9 FIRE EXTINGUISHER

Requirements for installing and checking the fire extinguisher.

USE OF THE MACHINE

3.6.1 CHECKS BEFORE STARTING THE ENGINE

Critical pre-operation checks including visual and daily inspections.

3.6.1.1 VISUAL CHECKS

Detailed list of visual checks to perform before starting the engine.

3.6.1.2 DAILY CHECKS

Essential daily checks before starting operations, including fluid levels.

3.6.2 STARTING THE ENGINE

Procedures for starting the engine under various climate conditions.

3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES

Procedure for starting the engine under normal temperature conditions.

3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES

Specific procedure for starting the engine in cold weather conditions, including preheating.

3.6.5 HOW TO MOVE THE MACHINE

General instructions and safety precautions for moving the machine.

3.6.5.1 STEERING (CHANGING DIRECTION)

Detailed instructions and diagrams for changing direction and performing counter-rotations.

3.6.5.2 MOVING ON SLOPES

Specific precautions and techniques for safely moving the machine on slopes.

PARKING THE MACHINE

3.7.1 PARKING ON LEVEL GROUND

Steps and safety measures for parking the machine on level ground.

3.7.2 PARKING ON SLOPES

Critical safety procedures for parking the machine on slopes.

STOPPING THE ENGINE

3.8 STOPPING THE ENGINE

Safe procedure for stopping the engine, including warm-down recommendations.

TRANSPORTING THE MACHINE ON MOTOR VEHICLES

3.9.1 LOADING AND UNLOADING THE MACHINE

Detailed steps and safety precautions for loading and unloading the machine onto vehicles.

LIFTING THE MACHINE

3.10 LIFTING THE MACHINE

Procedures and safety for lifting the machine using designated points.

MACHINE WITH CAB

Specific lifting points and procedures for machines equipped with a cab.

PRECAUTIONS TO BE TAKEN IN THE COLD SEASON

3.11.1 FUEL AND LUBRICANTS

Recommendations for fuel and oil types suitable for cold weather operation.

3.11.2 COOLANT

Antifreeze usage and safety precautions related to coolant in cold conditions.

3.11.3 BATTERY

Battery precautions in cold weather, including capacity and explosion risks.

3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK

End-of-work precautions for cold weather to prevent freezing and damage.

PRECAUTIONS TO BE TAKEN IN THE WARM SEASON

3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON

Seasonal checks and preparations for warm weather operation.

USING THE WORK EQUIPMENT

3.13.1 ORGANIZING THE WORK AREA

Steps to prepare the work area for efficient and safe operation of the work equipment.

3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS

How to position the machine correctly for digging, including slope and visibility considerations.

3.13.3 DIGGING METHOD

Correct techniques and safety advice for effective digging operations.

3.13.4 CHANGING THE BUCKET

Step-by-step guide for safely changing the bucket attachment.

USING THE MACHINE WITH VARIABLE TRACK GAUGE

3.14.1 HOW TO USE THE VARIABLE TRACK GAUGE

Procedure for adjusting the track gauge for maneuverability and stability.

3.14.2 ADJUSTING THE BLADE

How to adjust the blade for different track gauge configurations.

LONG PERIODS OF INACTIVITY

3.15.1 BEFORE THE PERIOD OF INACTIVITY

Comprehensive storage preparation steps to protect the machine during inactivity.

3.15.3 AFTER THE PERIOD OF INACTIVITY

Steps to take to prepare the machine for use after a long period of inactivity.

TROUBLESHOOTING

3.16.1 OCCURRENCES THAT ARE NOT FAILURES

Describes normal machine behaviors that are not indicative of malfunctions.

3.16.2 HOW TO REMOVE THE MACHINE

Procedures for safely removing the machine if it gets stuck or breaks down.

3.16.4 IF THE BATTERY IS DOWN

Safety precautions and procedures for dealing with a discharged battery.

3.16.4.1 STARTING WITH BOOSTER CABLES

Detailed instructions for safely starting the engine with booster cables.

3.16.5 OTHER TROUBLES

Troubleshooting common issues in electrical, hydraulic, and engine systems.

3.16.5.1 ELECTRICAL CIRCUIT

Common electrical issues, their causes, and recommended remedies.

3.16.5.2 HYDRAULIC SYSTEM

Common hydraulic system problems, their causes, and solutions.

3.16.5.3 ENGINE

Common engine issues, their causes, and recommended remedies.

MAINTENANCE

4.1 GUIDE TO MAINTENANCE

General guidelines and procedures for performing maintenance on the machine.

MAINTENANCE NOTES

4.2.1 NOTES REGARDING THE ENGINE

Important notes regarding engine oil and coolant maintenance.

4.2.1.1 ENGINE OIL

Selection and maintenance operations for engine oil.

4.2.1.2 COOLANT

Coolant function, level checks, and safety precautions.

4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM

Procedures and precautions for hydraulic system maintenance, including oil and filter changes.

4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING

List of wear parts, their codes, and recommended replacement intervals.

FUEL, COOLANT AND LUBRICANTS

4.3 FUEL, COOLANT AND LUBRICANTS

Guidelines for selecting and using fuel, coolant, and lubricants.

PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE

Table specifying fluids and lubricants based on ambient temperature.

LUBRICATION WITH GREASE

Table detailing lubrication points, consistency, and type of grease.

4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS

List of authorized HEES synthetic biodegradable hydraulic oils.

DRIVING TORQUES FOR SCREWS AND NUTS

4.4.1 STANDARD DRIVING TORQUES

Table of standard driving torques for various screw sizes and grades.

LUBRICATION

4.5.1 LUBRICATION DIAGRAM PC12R

Diagram showing lubrication points and intervals for PC12R.

4.5.2 LUBRICATION DIAGRAM PC12R HS (VARIABLE TRACK GAUGE)

Diagram showing lubrication points and intervals for PC12R HS.

4.5.3 LUBRICATION DIAGRAM PC15R

Diagram showing lubrication points and intervals for PC15R.

4.5.4 LUBRICATION DIAGRAM PC15R HS (VARIABLE TRACK GAUGE)

Diagram showing lubrication points and intervals for PC15R HS.

PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY

4.6.1 CRITICAL PARTS FOR SAFETY

Lists critical safety components in the fuel supply system that require periodic replacement.

HYDRAULIC SYSTEM PC12R-PC12R HS

Lists critical safety hydraulic pipes for PC12R/PC12R HS requiring periodic change.

HYDRAULIC SYSTEM PC15R-PC15R HS

Lists critical safety hydraulic pipes for PC15R/PC15R HS requiring periodic change.

OPERATOR’S SAFETY

Identifies the safety belt as a critical part for operator safety needing periodic replacement.

MAINTENANCE PLAN

4.7.1 WHEN REQUIRED

Maintenance tasks that should be performed as needed, with corresponding page references.

4.7.1.a WASHING THE COOLING CIRCUIT

Procedure for washing the cooling circuit to remove deposits.

4.7.1.d CHECKING THE STEEL TRACK TENSION

Procedure for checking and adjusting the tension of steel tracks.

4.7.1.e CHECKING THE RUBBER TRACKS

Criteria and procedure for checking rubber track wear and damage.

4.7.1.f CHECKING THE RUBBER TRACK TENSION

Procedure for checking and adjusting the tension of rubber tracks.

4.7.1.g CHANGING THE RUBBER TRACK

Step-by-step guide for safely removing and installing rubber tracks.

4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (BREAKER)

Specific maintenance intervals for machines equipped with a demolition hammer.

4.7.2.a CHANGING THE HYDRAULIC OIL FILTER

Procedure for changing the hydraulic oil filter, with interval chart.

4.7.3 CHECKS BEFORE STARTING

Routine checks to be performed before starting the engine.

4.7.3.a VARIOUS CHECKS

General pre-start checks covering screws, leaks, equipment wear, and safety items.

4.7.3.b CHECKING THE COOLANT LEVEL

Procedure for checking the coolant level in the compensation tank.

4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT

Procedure for checking hydraulic oil level, including conditions and precautions.

4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION

Maintenance tasks to be performed every 250 hours.

4.7.7.d CHANGING THE HYDRAULIC SYSTEM OIL FILTER

Procedure for changing the hydraulic system oil filter.

4.7.7.e CHANGING THE ENGINE OIL

Procedure for changing the engine oil, including draining and refilling.

4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION

Maintenance tasks to be performed every 500 hours.

4.7.9.b CHANGING THE FUEL FILTER

Procedure for changing the fuel filter and bleeding the circuit.

4.7.9.c CHANGING THE FUEL PUMP PRECLEANER

Procedure for changing the fuel pump precleaner and bleeding the circuit.

4.7.9.d CHANGING THE AIR CLEANER CARTRIDGE

Procedure for changing the air cleaner cartridge.

4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION

Maintenance tasks to be performed every 2000 hours.

4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER

Procedure for changing hydraulic oil and cleaning the suction filter.

4.7.11.b CHANGING THE COOLANT

Procedure for changing the coolant, including circuit flushing.

TECHNICAL SPECIFICATIONS

5.1 TECHNICAL DATA

Detailed technical data and specifications for the machine models.

5.1.1 STANDARD OVERALL DIMENSIONS PC12R

Drawings showing overall dimensions for PC12R with cab and canopy.

5.1.2 TECHNICAL CHARACTERISTICS PC12R

Key technical specifications for the PC12R model, including mass, engine, and electrical system.

5.1.3 STANDARD OVERALL DIMENSIONS PC12R HS (VARIABLE TRACK GAUGE)

Drawings showing overall dimensions for PC12R HS with cab and canopy.

5.1.4 TECHNICAL CHARACTERISTICS PC12R HS (VARIABLE TRACK GAUGE)

Key technical specifications for the PC12R HS model.

5.1.5 STANDARD OVERALL DIMENSIONS PC15R

Drawings showing overall dimensions for PC15R with cab and canopy.

5.1.6 TECHNICAL CHARACTERISTICS PC15R

Key technical specifications for the PC15R model.

5.1.9 LIFTING CAPACITY WITH RAISED BLADE PC12R

Lifting capacity data for PC12R with raised blade, showing load charts.

5.1.10 LIFTING CAPACITY WITH LOWERED BLADE PC12R

Lifting capacity data for PC12R with lowered blade, showing load charts.

5.1.11 LIFTING CAPACITY WITH RAISED BLADE PC12R HS (VARIABLE TRACK GAUGE NARROWED)

Lifting capacity for PC12R HS (narrowed) with raised blade.

5.1.12 LIFTING CAPACITY WITH RAISED BLADE PC12R HS (VARIABLE TRACK GAUGE WIDENED)

Lifting capacity for PC12R HS (widened) with raised blade.

5.1.13 LIFTING CAPACITY WITH LOWERED BLADE PC12R HS (VARIABLE TRACK GAUGE NARROWED)

Lifting capacity for PC12R HS (narrowed) with lowered blade.

5.1.14 LIFTING CAPACITY WITH LOWERED BLADE PC12R HS (VARIABLE TRACK GAUGE WIDENED)

Lifting capacity for PC12R HS (widened) with lowered blade.

5.1.15 LIFTING CAPACITY WITH RAISED BLADE PC15R

Lifting capacity data for PC15R with raised blade, showing load charts.

5.1.16 LIFTING CAPACITY LOWERED BLADE PC15R

Lifting capacity data for PC15R with lowered blade, showing load charts.

5.1.17 LIFTING CAPACITY WITH RAISED BLADE PC15R HS (VARIABLE TRACK GAUGE NARROWED)

Lifting capacity for PC15R HS (narrowed) with raised blade.

5.1.18 LIFTING CAPACITY WITH RAISED BLADE PC15R HS (VARIABLE TRACK GAUGE WIDENED)

Lifting capacity for PC15R HS (widened) with raised blade.

5.1.19 LIFTING CAPACITY WITH LOWERED BLADE PC15R HS (VARIABLE TRACK GAUGE NARROWED)

Lifting capacity for PC15R HS (narrowed) with lowered blade.

5.1.20 LIFTING CAPACITY WITH LOWERED BLADE PC15R HS (VARIABLE TRACK GAUGE WIDENED)

Lifting capacity for PC15R HS (widened) with lowered blade.

AUTHORIZED OPTIONAL EQUIPMENT

6.1.1 PRECAUTIONS REGARDING SAFETY

Safety rules for installing and using optional equipment.

6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT

Warnings about installing optional equipment, especially regarding stability and procedures.

6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT

Specifications for various optional equipment attachments, including dimensions and operating parameters.

ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER)

6.2.1 DESCRIPTION AND CONTROL

How the demolition hammer is controlled via a pedal and distributor.

6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED

Guidelines for effective use of the demolition hammer, including tool choice and material.

6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER

Procedures for installing and removing the demolition hammer, including hydraulic connections.

6.2.3.1 INSTALLING THE HAMMER

Step-by-step guide for installing the demolition hammer, including hydraulic connections.

6.2.3.2 REMOVING THE HAMMER

Step-by-step guide for safely removing the demolition hammer.

6.2.4 MAINTENANCE

General maintenance requirements for the demolition hammer.

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